Wheelabrator South Broward – Hollywood, Florida, USA
Transfer Station / Tipping Floor Bay #9
(performed by an Epoxytec certfied applicator)
Rehabilitative and protective solutions for the solid waste industry pertaining to corrosion induced by wear and chemical attack due to debris, scrap, refuse, and various solid and liquid waste.
It was with great pleasure to present solutions and services to Wheelabrator South Broward, a Waste Management company. Wheelabrator South Broward requested a solution from Epoxytec to address maintenance related rehabilitative and protective solutions in order to remedy current structural floor concerns in need of repair and apply preventive maintenance measures to combat corrosion and wear with superior materials as an alternative to current traditional methods in order to further extend the life expectancy of Wheelabrator’s structures and assets, which in turn, will increase productivity.
In this case study, Wheelabrator S. Broward was experiencing ultra-high corrosion and loss of concrete at the tipping floor areas of their facility. Tipping floors at the Transfer Station are designed as an area where waste management garbage dump trucks empty municipal solid waste (MSW) into a refuse bunker for consolidation. MSW consists of a variety of unknown corrosives and abusive ruble. Within the matrix of the rubbish, various chemicals and organics are present. This is quite noticeable because of the intensely foul and putrid odors. Most facilities try to aerate the trash stacks, which unintentionally breeds further microbial induced corrosion.
Because the tipping floor is designed as a transfer station, the use of heavy equipment is essential. Bulldozer blades and other heavy mechanical machinery are constantly pushing the collected trash into piles and ultimately into the refuse bunker where it is collected. This method of brute and forceful transfer mechanics causes extreme wear, and the wearing effects are coupled with the abuses of heavy solid trash – mattresses, wood, boulders, heavy metal objects, etc.
An endless cycle of wear, impact, and abrasion, catalyzed with chemical corrosives results in weakened concrete and accelerated wear at an unprecedented rate. The tipping floor is the source of productivity for waste management processing plants, and loss of time due to slowdowns or temporary shutdowns are a large hindrance on Wheelabrator’s operations. Finding a way to extend the maintenance cycle was imperative, Epoxytec was able to help.
Preparation was necessary to decontaminate and clean the concrete, rid the weakened surface, and expose the substrate for inspection and preparation before application of the new epoxy substrate solution proposed and developed by Epoxytec.
Upon examining the tipping floor bays, Epoxytec recommended utilizing a custom manufactured system designed just for tipping floor rehab – Epoxytec 17G (ultra-high density epoxy grout).
The Epoxytec 17G solution is a structural wear and abrasion resistant material, with an enhanced proprietary granule embedment and optional graphite blending to decrease the coefficient of friction and wear. The material is “green” and environmentally friendly, exhibiting a safe 100% solid formulation (no VOCs, no solvents, no fumes). Using the system provides Wheelabrator an ultra-high build material to combat wear with a quick return-to-service, thus extending the life-expectancy of the floor and improving downtime cycles to provide increased productivity.
Unlike slurry troughs, high velocity pumps, or fine slit abrasion which is typical when trouble-shooting abrasion; Wheelabrator is rather experiencing a “sliding” friction-based abrasive condition with heavy abuse. Wheelabrator’s concrete floors are exposed to a cycle of impact, disposal on top of concrete and then a metal-to-concrete sliding force (also frictional abuse of other materials as well).
This “sliding” abrasive force was the focus of our study, which ultimately helped formulate Epoxytec’s recommendation utilizing 17G.
Fighting abrasion with abrasion-resistant fillers is great when combating a force with a stronger material filler than the opposing force (brute force results).
Other Considerations and Indirect Advantages:
When dozer blades and refuse slide across the surface, a small amount of soft (mush-state) and corroded concrete goes with it; the catalyst of weakening concrete is multiplied by constant daily cycles and contributes to the accelerated wear rate on concrete tipping floors. The original concrete has enough challenges to deal with regarding abrasion alone; if the concrete is in a constant state of weakening, then the concrete never stood a chance in a tipping floor environment.
One of Epoxytec’s goals were to shift the maintenance cycle from the costly downtime of rebuilding concrete (slow process, long down time) to servicing the coating system with easy repairs that are fast, simple-to-apply, and quick curing for rapid turn-around and overall better performance. Doing this will be a key to a long-term successful and protective system.
PouringEpoxytec 17G onto the prepared area. The system target thickness is one inch (1000 mils / 1″).
The first section to be installed is directly before the refuse bunker. The section experiences the worst wear and is considered a priority repair area for theEpoxytec 17G to structurally restore, cure and protect.
Using the undercut method as describe previously, provided a flush transitional edge to minimize any impact.